Method and apparatus for a composite concrete panel with transversely oriented carbon fiber reinforcement

Abstract

The present invention relates to building panels used in the construction industry, and more specifically composite building panels comprised of an insulative core, concrete, and carbon fiber which are preformed, cast and transported to a building site for modular construction.

What is claimed is:  
     
       1. A composite building panel, comprising: 
       an insulative core having an outer surface and an inner surface;  
       an exterior layer of concrete positioned substantially adjacent said outer surface of said insulative core;  
       an interior layer of concrete positioned substantially adjacent said inner surface of said insulative core;  
       a plurality of carbon fiber strands extending in a substantially diagonal pattern between said exterior layer of concrete, through said insulative core, and said interior layer of concrete; and  
       an interior carbon fiber grid positioned proximate to said inner surface of said insulative core and at least partially interconnected to said plurality of carbon fiber strands, and an exterior carbon fiber grid positioned proximate to said outer surface of said insulative core and at least partially interconnected to said plurality of carbon fiber strands.  
     
     
       2. The composite building panel of  claim 1 , further comprising a plurality of compression pins extending between said outer surface and said inner surface of said insulative core, wherein said compressive strength of said composite building panel is increased. 
     
     
       3. The composite building panel of  claim 2 , wherein said plurality of compression pins are comprised of at least one of a plastic, a composite and a fiberglass material. 
     
     
       4. The composite building panel of  claim 2 , wherein said composite building panel has a compressive strength of at least about 40 psi when a force is applied in a direction substantially normal to a longitudinal plane of said building panel. 
     
     
       5. The composite building panel of  claim 1 , wherein said plurality of carbon fiber strands are oriented at an angle of at least about 35 degrees with respect to a vertical longitudinal plane of said composite building panel. 
     
     
       6. The composite building panel of  claim 1 , further comprising at least one utility conduit extending through at least a portion of said insulative core which is adapted for receiving a utility line. 
     
     
       7. The composite building panel of  claim 6 , wherein said at least one utility conduit is comprised of at least one of a plastic, a metal, a vinyl clad metal and a fiberglass. 
     
     
       8. The composite building panel of  claim 1 , further comprising a cladding material positioned substantially adjacent to said exterior layer of concrete. 
     
     
       9. The composite building panel of  claim 8 , wherein said cladding material comprises a plurality of bricks having a substantially trapezoidal shape. 
     
     
       10. The composite building panel of  claim 8 , further comprising a protective layer of paraffin applied to an exterior surface of said cladding material. 
     
     
       11. The composite building panel of  claim 1 , further comprising a substantially impermeable vapor barrier positioned adjacent to said insulative core. 
     
     
       12. The composite building panel of  claim 11 , wherein said substantially impermeable vapor barrier comprises a plastic material. 
     
     
       13. The composite building panel of  claim 1 , wherein said insulative core is comprised of an expanded polystyrene material. 
     
     
       14. A composite building panel adapted for constructing a modular structure, comprising: 
       an insulative core having an interior surface and an exterior surface;  
       a substantially impermeable vapor barrier positioned adjacent to said exterior surface of said insulative core;  
       a first carbon fiber grid positioned proximate to said exterior surface of said insulative core comprising a plurality of first carbon fibers oriented in a first direction which are operably interconnected to a plurality of second carbon fibers oriented in a second direction;  
       a second carbon fiber grid positioned proximate to said interior surface of said insulative core comprising a plurality of first carbon fibers oriented in a first direction which are operably interconnected to a plurality of second carbon fibers oriented in a second direction;  
       a plurality of carbon fiber strands interconnecting said first carbon fiber grid and said second carbon fiber grid and extending through said insulative core in a substantially diagonal orientation;  
       an exterior layer of concrete positioned substantially adjacent to said exterior surface of said insulative core;  
       an interior layer of concrete positioned substantially adjacent to said interior surface of said insulative core, wherein said insulative core, said exterior layer of concrete, said interior layer of concrete, said first carbon fiber grid and said second carbon fiber grid are interconnected with said plurality of carbon fiber strands.  
     
     
       15. The composite building panel of  claim 14 , further comprising a plurality of compression pins extending between said interior surface and said exterior surface of said insulative core, wherein said compressive strength of said insulative core is increased. 
     
     
       16. The composite building panel of  claim 14 , wherein said interior layer of concrete has a density of no greater than about 90 pounds per cubic foot. 
     
     
       17. The composite building panel of  claim 14 , further comprising at least one utility conduit positioned at least partially in said insulative core which is adapted for receiving a service wire or cable. 
     
     
       18. The composite building panel of  claim 14 , wherein said first carbon fiber grid is substantially embedded in said exterior layer of concrete and said second carbon fiber grid is substantially embedded in said interior layer of concrete. 
     
     
       19. The composite building panel of  claim 14 , further comprising a cladding material positioned substantially adjacent to said exterior layer of concrete. 
     
     
       20. A method for manufacturing a composite, carbon reinforced building panel, comprising the steps of: 
       providing an insulative core having an interior surface and an exterior surface;  
       positioning a plurality of carbon fiber strands which extend between said interior surface and said exterior surface of said insulative core and which are oriented in a substantially diagonal direction with respect to a longitudinal plane of said insulative core;  
       positioning a first carbon fiber grid adjacent to said interior surface of said insulative core;  
       positioning a second carbon fiber grid adjacent to said exterior surface of said insulative core;  
       interconnecting said plurality of carbon fiber strands to said first carbon fiber grid and said second carbon fiber grid;  
       pouring an interior layer of concrete adjacent said interior surface of said insulative core;  
       pouring an exterior layer of concrete adjacent said exterior surface of said insulative core;  
       curing said interior layer of concrete and said exterior layer of concrete, wherein said insulative core, said plurality of carbon fiber strands, said first carbon fiber grid and said second carbon fiber grid are integrally interconnected.  
     
     
       21. The method of  claim 20 , further comprising the step of positioning a plurality of compression pins in said insulative core, wherein a compressive strength of said composite, carbon reinforced building panel is enhanced. 
     
     
       22. The method of  claim 20 , comprising the step of positioning a vapor barrier adjacent to said exterior surface of said insulative core. 
     
     
       23. The method of  claim 20 , further comprising the step of interconnecting a cladding material to said exterior layer of concrete. 
     
     
       24. The method of  claim 20 , further comprising the step of positioning a utility conduit at least partially in said insulative core which is adapted to receive at least one utility line. 
     
     
       25. The method of  claim 20 , wherein said plurality of carbon fiber strands are operably interconnected at a plurality of intersection points.